Combined board and process of forming the same.



106. COMPOSITIONS, Y My x, Examiner comma on PLASTIC.

1. D. CARTER.

COMBINED BOARD AND PROCESS OF FORMlNG THE SAME.

APPLICATION FILED DEC. 31,1914.

1 1 88,040 Patented June 20, 1916.

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Egg. F J8" Z/ 1 9 15 1 J 5 w I 3% 6 INVENTOR (john/Z7. C an/e] WITNESSES c g Q 6 z a" .W BY ATTORNEYS J'OEN' D. CARTER, OF LANSDOWNE, PENNSYLVANIA.

COMBINED BOARD AND PROCESS OF FORMING THE SAME.

Specification of Letters Patent.

Patented June 20, 1916.

Application filed December 31, 1914. Serial No. 879 856.

To all whom it may concern:

Be it known that I, JOHN D. CARTER, a citizen of the United States, and a resident of Lansdowne, in the county of Delaware, State of Pennsylvania, have invented certain new and useful Improvements in Combined Boards and Processes of Forming the Same, of which the following is a specification, reference being had to the accompanying drawing: L

My invention relates more especially to that class of combined boards commercially known as composite boards which are formed by suitably securing together a plurality of plies or sheets of paper, straw board, card board, or somewhat similar material, to produce a combined board suitable for use in the various arts and especially in the building trades for wall sheathing and the like, and among the principal objects ,of my invention are to produce a combined board of this character in which the various plies of material shall be securely and evenly associated to produce a finished article having the characteristics of an integral homogeneous unit, and in which the plies will not separate when in use, either through careless handling, the action of moisture or other causes.

Further objects of my invention are to provide a method of preparing a combined board of this character, in which the action of the adhesive employed to unite the various plies may be readily controlled by the operator to produce the most elficient results, and which may be readily and economically carried out on a commercial scale.

Still further objects of my invention are to provide a combined board which may be manufactured at a low cost and by means of machinery now employed, without materially changing the same.

My invention further comprises all of the other various novel characteristics and featimes hereinafter more definitely specified.

In the accompanying drawing, I have diagrammatically illustrated my improved board both during the process of manufac ture, and in the finished state, Figures 1 and 2 representing, on a greatly enlarged scale, a fragmentary transverse section of a portion of one form ofthe board, respectively during the process of formation and as the finished article; Figs. 3 and 4 are similar views of a slightly modified form of the"- board; Figs. 5 and 6 are similar views of another slightly modified form thereof, and Figs. 7 and 8 are similar views of a still further slightly modified form of the article.

In the preparation of a board in accordance with my invention and which may consist of any number of plies of material, such as paper or the like, I provide means whereby the various plies may be coated with a suitable adhesive and thereafter combined, under pressure, in any suitable manner, and withor without the employment of heat, to produce the finished article. Considering now a combined board consisting of but two plies 1 and 2 of material, as illustrated in Figs. 1 to 4 inclusive, I may apply a coating of adhesive 4, preferably of substantially even thickness, to both of the adjacent faces of the plies of material as shown in Fig. 1,, or I may apply a similar coating 4' to only one of the adjacent faces and thereafter cause the plies to be brought together, preferably under suitable pressure, and with or without the employment of heat, whereby after the adhesive has dried or set the adjacent plies will be united to form the completed board, as shown in Figs. 2 and 4, a layer 7 of the adhesive remaining between the adjacent faces of the plies. In case the adhesive has been applied to both adjacent faces, as in Fig. 1, the layer 7 within the finished board may be slightly thicker than if only a single coating of adhesive is used, as in that form of the board shown in Figs. 3 and 4.

In Figs. 5 and 6, 7 and 8, I have diagrammatically illustrated a board composed of more than two plies of material. In Fig. 5 I have shown such a board having three plies, 8, 9' and 10, inthe process of formaby bringing the several coated surfaces together, a relatively thick layer 13 of thev adhesive is formed between each of the several plies. InFigs. 7 and 8 is shown a board also having three plies, 8, 9' and 10, Fig. 7

showing the board in the process of formal tion, the central plly 9' being coated upon both sides with t e adhesive 12', and the outer plies 8'. and 10 having no adhesive '95 tion, the central ply 9 being coated with the I Xz L 88,0 60

106. COMPOSITIONS,

COATING OR PLASTIC.

tended still produced, I prefer,

thickness, and that if more than three plies.

are used the inner plies may be coated with the adhesive upon both sides and the outer plies upon their u per and lower sides respectively, or all '0 the plies but onemay be coated upon one of their surfaces only, in the manner shown in Fig. 3, and then brought together and preferably compressed by' suitable means. Moreover, if desired, two or more plies of material may be combined as shown in Figs. 2 or 4 and then, these combined plies united with other combined or single plies to form a still thicker board, so that by combining a suflicient number of single or combined plies, a finished article of practically any desired thickness may be produced.

In the formation of my combined board, I prefer to employ an adhesive comprising a solution of sodium silicate mixed with a suit- ?rbIe quantity of hydrous clay, preferably in finely ground or divided'form, which -material I have found has the property of taking up a relatively large amount of the-silicate solution without reaching such a state of excessive dryness as to prevent the commercial employment of the mixture as an adhesive. Owing to this property of the hydrous clay, I am enabled to employ a solution of sodium silicate of a relatively low degree. of concentration, and still obtain a suficient' adhesive effect to firmly unite the plies together, thus producing a relatively slow drying adhesive 'which will not discolor or otherwise injuriously affect the material composing the plies, which -flows readily over the surface thereof, and which may be produced readily and economically. While the proportions of the ingredients of the adhesive may be varied, between limits, and a material wtisfactory for the urposes inr example, to employ a solution of sodium silicate in h in silic and of 'a concen ra 1on approxi mat 3 mg 4 Baum, to which may be added substantially per cent. of its weight of the hydrous clay which proportions, I find, proiiea most satisfactory adhesive, the profduct so obtained being capable of exerting a maximum adhesive effect without causing discolorations or other objectionable results in the plies of material employed which might arise were a silicate solution of greater: concentration employed. Howe ver,

Reference the proportions of the ingredients of the ad- Examiner heslye may as heretofore stated be varied as may be desired between limits, depending quired, as well as upon the particular characteristics of the hydrous clay employed, and also upon the time in which it is desired to have the adhesive dry or set, during the operation of combining the plies. This time may be readily regulated and controlled by the operator'with an adhesive of this character in which a relatively dilute sodium silicate solution may be employed, without a sacrifice of adhesivevproperties, as such a solution dries more slowly than the more concentrated sodium silicate solutions and therebyipermits more exact control of the somewhat upon the degree of adhesion resetting of the material during the process I of combining the plies to. form the completed board. A further advantage arising from the employment of an adhesive of thecharacter described arises from the fact that the same has but a relatively slight tendency to penetrate and be absorbed in the material composing the plies, whereby only a relatively small amount of the adhesive need be utilized to secure substantially perfect adhesion between the various plies, and in addition, I have found that an adhesive of this character flows readily during the process of coating the plies and is thus well adapted for use in machines designed to perform this operation.

I do not desire to limit myself to the formation of a Hat board suitable for use as a wall board and the like in building constructions,

.as it will be evident that combined board myself to any specific proportions of the ingredients composing the adhesive, or to any specific hydrous clay, as the same may be vamed to suit existing conditions or to attain.

desired results, and I may further utilize any suitable means convenient for spreadi the adhesive upon the plies of material an for combining the plies to form the finished product, without departing frm the spirit and scope of my invention as defined in the appended claims.

-Furthermore I do not intend or desire to claim in this application the particular adhesive hereinbefore described, as the sameforms the subject matter of, and is claimed m, my co-pending application for Letters Patent of the United States, filed May 19, 1916, Serial No.'98,515.

'Having ,thus described my invention, I

claim and desire to rotect by Letters Pat- 'ent of the United tates:

A bined board comprising a plurality of plies 1. As an article of manufacture a c0mbined board-comprising a plurality of plies of material and an adhesive comprising a splution of sodium silicate and hydrous c y- 2. As an article of manufacture a combined board comprising a plurality of plies of material and an adhesive comprising a relatively weak solution of sodium silicate and hydrous clay.

3. As an article of manufacture a comof material and an adhesive uniting said plies and comprising a dilute solution of sodium silicate and finely powdered hydrous clay.

4.. As an article of manufacture a combined board comprising a plurality of plies of material, and a layer of adhesive material between the adjacent faces of said plies, said material comprising a dilute solution of spdium silicate and finely divided hydrous cay.

5. 'As an article of manufacture a combined board comprising a plurality of plies of paper and an adhesive uniting said plies, said adhesive comprising a solution of sodium silicate high in silica and of substantially 34 Baum concentration to which has been added substantially 80% by weight of finely divided hydrous clay.

6. The process of forming a combined board which comprises coating one or more plies of material with an adhesive compris ing sodium silicate and hydrous clay, and uniting said coated ply with an adjacent 1y. p 7. The process of forming a combined board having a plurality of plies of material, which consists in coating the surface another of said plies.

of one or more of said plies with a mixture comprising a solution of sodium silicate and hydrous clay, bringing said coated surface into contact with another of said plies, and

causing said mixture to set to unite said plies.

8. The process of forming a combined board having a plurality of plies of material,-'which consists in coating one of said plies with a mixture comprising a relatively dilute solution of sodium silicate and hydrous clay and then uniting said ply with lution of sodium silicate of substantially 34 Baum concentration to which has been added substantially 80% of its weight of hydrous clay, bringing ano her ply of material adjacent said coated surface and applying pressure to cause. saidadhesive to unite said plies. v

In witness whereof, I have hereunto set my hand this 30th day of December, A. D.

, JOHN D. CARTER.- Witnesses:

GEORGE K. HELBERT, ALEXANDER PARK. 

